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Workshop Materials

Workshop Materials Orthotic Materials

Innovative Materials and Workshop Solutions

Algeos offers a comprehensive range of orthotic, prosthetic, and footwear components for manufacturers of medical devices. Our product range includes everything from materials for custom orthotic fabrication to components for specialised footwear and ankle-foot orthoses (AFOs). With a focus on quality and innovation, Algeos provides solutions to meet the diverse needs of patients and practitioners in the field of orthotics and prosthetics.

Algeos also stock products for shoe repairers, as well as boat makers, DIY enthusiasts, prop makers, and other users of foams, corks, plastic, adhesives, and orthotic components. 

Materials for Orthotic and Prosthetic Applications

The field of orthotics and prosthetics (O&P) has evolved significantly from the days of using leather, wood, and steel. Today, professionals in this field have access to a wide array of materials, each offering unique properties that enhance the functionality, comfort, and durability of O&P devices. This guide explores the various materials used in orthotic and prosthetic applications, including natural and synthetic options, textiles, metals, and chemicals.

Decision-Making Tools for Material Selection

Selecting the right material for any given O&P application involves considering numerous factors:

  • Patient's Profile: Age, weight, general health, occupation, hobbies, climate, and insurance coverage.
  • Material Properties: Firmness, flexibility, rigidity, adjustability, and strength.
  • Environmental Considerations: Exposure to body fluids, temperature fluctuations, and potential for corrosion.

Natural Materials

Leather

Leather is valued for its firmness, water repellency, flexibility, durability, and breathability. It is commonly used in straps, suspension cuffs, and various orthotic devices due to its shock absorption and control properties. However, leather can be bulkier than synthetic materials and less durable under repeated soaking.

Cork

Cork, harvested from the bark of cork oak trees, is a renewable, lightweight, resilient, and shock-absorbent material. It is often blended with other substances like rubber and thermoplastics to enhance its properties. Cork is commonly used in arch supports, forefoot extensions, and as a base layer for orthotic devices.

Synthetic Materials

Thermoplastics

Thermoplastics are a cornerstone of modern O&P materials due to their flexibility, durability, and ease of moulding. Common types include:

  • Polypropylene: Rigid and impact-resistant, used in body jackets and ankle-foot orthoses (AFOs).
  • Polyethylene (PE): Available in varying densities, PE is used for flexible socket interfaces and orthotic splints.
  • Acrylonitrile Butadiene Styrene (ABS): Known for its strength and stiffness, ABS is used in various structural components.

Foams and Gels

Foams and gels provide cushioning, shock absorption, and pressure relief. They come in different types:

  • Polyurethane (PU) Foams: Durable and non-compressible, used for arch supports and high-impact applications.
  • Ethyl Vinyl Acetate (EVA) Foams: Lightweight and flexible, EVA foams are used in insoles and cushioning materials.
  • Silicone Gels: Provide comfort and protection, often used in distal end pads and gel liners for prosthetic sockets.

Carbon Composites

Carbon composites, including carbon fiber reinforced plastic (CFRP), offer excellent strength-to-weight ratios and are used in high-performance prosthetic and orthotic devices. These materials are ideal for active individuals or those requiring specialised orthotic designs.

Textiles

Textiles play a critical role in the reinforcement of O&P devices through the lamination process. Common textiles include:

  • Nylon: Adds durability and flexibility, used in socket laminations and orthotic devices.
  • Fiberglass: Provides strength and elasticity, used in various reinforcement applications.
  • Kevlar: Known for its high tensile strength and resistance to impact, used in prosthetic sockets and high-stress areas.

Metals

Metals are essential for their strength, durability, and versatility. Common metals used in O&P applications include:

  • Stainless Steel: High resistance to corrosion and stiffness, used in joints and support structures.
  • Titanium: Lightweight yet strong, ideal for implants and prosthetic limbs.
  • Aluminium: Lightweight and easily machined, used in structural supports.
  • Copper: Malleable and ductile, used in smaller components like rivets and screws.

Chemicals

Chemicals are used for various purposes, including as solvents and in the production of resins:

  • Styrene: Used in making plastics and resins, though it poses health risks.
  • Acetone: A common solvent for plastics and synthetic fibres, safer than other solvents but still requires careful handling.
  • Epoxy Resins: Known for their high tensile strength and flexibility, used in high-strength bonding applications.
  • Polyester Resins: Less expensive but more brittle and less durable than epoxy resins, used in lighter applications.

Protective Measures

When working with materials and chemicals, safety is paramount:

  • Ventilation and Filtration: Essential for managing dust and fumes.
  • Personal Protective Equipment (PPE): Including gloves, masks, and eye protection to prevent exposure to harmful substances.
  • Proper Training and Handling: Regular training on best practices to minimise risks.

The diverse range of materials available for O&P applications allows for tailored solutions that meet the specific needs of patients. By understanding the properties and appropriate uses of each material, O&P professionals can design and fabricate devices that improve patient outcomes and enhance quality of life. For further learning and self-assessment, resources such as Quizlet offer valuable tools for mastering the knowledge presented here.


Top Quality Materials, Unsurpassed Conversion Services

Algeos prides itself on offering top quality products and unsurpassed services. Our aim is to become a ‘one stop shop’ for all your Orthotic & Prosthetic requirements. Algeos supply and manufacture the widest range of appliance making materials available anywhere in the World, including foams, carbon fibre composites, metal items and plastics. With our own in-house cutting, splitting and laminating machines on site, we are able to manufacture and convert materials to almost any specification.


Aortha  - Orthotic Materials Technology

The Aortha brand was established in 2010 to bring all Algeos materials and components under one brand, in order to build a strong international brand that clinicians and technicians can trust. Aortha includes EVA, Carbon Composites, Thermoplastics, Transfer papers for AFOs, Lower Limb Orthotic Joint Components and Lower Limb Prosthetic Components.

Over the last few years there has been a major change to the global Foot Orthotic Industry and the use of CAD-CAM and 3D Printing  systems. Aortha has been able to be at the forefront of material technology to develop an entire range including EVA, Plastic and PU in multiple densities by working with all the major Orthotic CAD-CAM players.